In manufacturing, we often focus on high costs: raw materials, energy, logistics. But there is also an inconspicuous „cargo stowaway“: glue.
In reality, seemingly insignificant adhesive leaks can represent thousands of euros a year going down the drain – literally.
Bonding systems run for years without a fundamental audit analysis. The machines, the nozzles, the adhesive used, the cleaning and maintenance techniques, all operate in secret. Rework, over-consumption, frequent part changes or stopped production are all symptoms that something is not optimal.
Audit of adhesive systemsoffered by AGGLU is like a preventive check-up at the doctor’s office to avoid something more serious. It’s a tool that allows you to avoid waste, increase efficiency and save THOUSANDS of Euros per year without the need for large capital investments.
What is an audit of adhesive systems?
Very briefly, what our audit looks like:
The bottom line is that we’re not trying to jump right into a costly new investment, but to save you as much money as possible. That’s what auditing is all about, saving costs where you can save them.
Why auditing adhesive systems is worthwhile
Benefit | What it brings in practice |
|---|---|
Reduced adhesive consumption without compromising joint quality | Dosing optimisation, replacement of inefficient nozzles, application control → less overflow, less waste |
Less downtime, fewer disruptions | Dirty nozzles, worse cleaning/maintenance → more frequent downtime. An audit helps to detect these weaknesses before they become a problem. |
Better equipment lifetime | Proper maintenance, replacement of worn parts, cleaning – all these contribute to making the equipment last for more years. |
Material and energy savings | Less waste, optimal dosage, selection of suitable adhesives with more efficient behaviour, less waste disposal costs. |
Increased production stability and product quality | Fewer defects, better consistency of joints, fewer complaints – the result is a better reputation and greater reliability for customers. |
When an audit just brings you the most benefit
If you recognise yourself on one or more of these points, an audit is worth considering:
What the audit shows in practice
Based on our audits at various manufacturing sites, similar patterns are repeated:
High amount of waste during cleaning
- On average, 1-5 kg of glue per day ends up as waste.
- per year, this means hundreds of kilograms and thousands of euros in losses (real example: 832 kg of waste = €5,769 per year).
Losses associated with maintenance
- servicing of older machines (spare parts, cylinder changes, oil changes) is usually in the thousands of euros per year.
- if the disposal of waste adhesive and cleaning agents is added, the annual costs can exceed 10 000 €.
Reduced joint quality and higher production waste
- crooked slot head or worn rollers cause inconsistent application.
- Result: aesthetic defects, weaker strength, complaints or the need to rework the product.
Inefficient use of energy
- too wide cylinders or outdated heating systems lead to excessive energy consumption.
- These are „hidden costs“ that are often not captured by normal accounting, but actually reduce efficiency.
Why machines older than 10 years pose a risk
Our experience confirms that after approx. 10 years of operation:
- occurs wear of key parts (cylinders, slot heads, seals),
- spare parts are becoming less and less available,
- consumption of glue and waste is increasing,
- decreases reliability and downtime increases.
Modern machines today offer higher accuracy, lower power consumption and automated functionsthat significantly reduce the need for manual maintenance.
What can you do right away?
- Establish an internal audit checklist: use of a questionnaire similar to ours in AGGLU as a regular audit tool.
- Measure material and adhesive consumption: compare how much glue goes into the product vs. how much is lost (overflow, clogging, incorrect dosage).
- Check cleaning and maintenance processes: whether they are regular, whether the right products are used, whether staff are trained.
- Evaluate alternative adhesive types and application: you may find a better type or system that reduces material and operating costs without negatively impacting quality.
We have also prepared a shorter questionnaire for you. It will give us basic information about the status of your adhesive systems. It’s not all we need to know, but it’s enough for an introduction. If you fill it in and it turns out that you need servicing, we will arrange a visit to your facilities. Together, we’ll do a quick estimate of potential savings and suggest specific actions.
Let’s find out if auditing can be a tool for greater efficiency and savings in your production.
Just click and fill in. 
